Processing substrate and/or support surface

ABSTRACT

A processing substrate comprises a first material having a liquid-permeable surface, a second material disposed adjacent to the first material and having a liquid-absorbent portion and a third material disposed adjacent the second material and having a liquid-impermeable surface.

RELATED CASES

[0001] This application is a continuation-in-part of Ser. No.09/677,663, filed Oct. 2, 2000, entitled “Processing Substrate and/orSupport Surface.”

TECHNICAL FIELD

[0002] The present invention relates generally to protective media, and,more particularly, to a processing substrate and/or support surfacewhich is disposable.

BACKGROUND ART

[0003] Management of bacteria, liquids, fats and other waste during thepreparation and handling of foods is of concern in food handling areas.Typically, such areas include the kitchen, although modern lifestylesinclude out-of-home occasions such as social and recreational gatheringswhere food is prepared, transported and/or served outside of thekitchen. Foods of particular concern from the standpoint of possibilityof food-borne illness are fish, fowl and ground meats; although allfoods present some degree of risk. Current media articles discuss thefact that the common cutting boards used in the preparation of foods area source of food contamination. Other commonly used food preparationsurfaces, such as countertops, also present some risk. Specifically, ithas been found that bacteria can become entrapped in surfaceimperfections of the cutting surface, resulting in a surface that isdifficult, if not impossible, to clean and/or sterilize. The cuttingsurface thus becomes capable of transferring bacteria to other foods,which provides a favorable media for pathogens to proliferate, resultingin an increased potential for food-borne illness, particularly whencontact is had with high-risk foods. In fact, some foods considered tobe pathogenically low-risk, such as fresh fruits and vegetables canbecome contaminated, waiting for the right environment for the bacteriato proliferate. Illnesses from mild to severe or even fatal can result.

[0004] Another issue with cutting boards is the transfer of juices fromthe cutting board to other surfaces in the kitchen due to the fact thatthe cutting board is normally not designed to capture and contain juicesduring the cutting operation and thereafter through final disposal. Inaddition to the inconvenience of having to clean the countertop or othersurface(s) exposed to the juices, a possibility exists that other fooditems placed on such surface(s) may be cross-contaminated.

[0005] Products are in the marketplace today that attempt to addressissues of liquid, fat, and bacteria management during cutting andgeneral food preparation. However, these products fall short of optimumin one way or another. Specifically, they do not absorb, are not cutresistant, and/or fail to provide an effective bacteria barrier betweenthe food being handled and the work surface. Also, bacteria are retainedwhich can cause contamination during subsequent use.

[0006] In addition to the foregoing, most, if not all, food preparationsurfaces lack one or more of the following attributes:

[0007] 1. a single use, disposable cutting surface that is virtually cutresistant and also entraps and holds waste and bacteria;

[0008] 2. a food preparation surface which prevents food movement duringcutting;

[0009] 3. a food preparation surface which prevents and/or selectivelymanages movement thereof on the counter top during cutting;

[0010] 4. a single-use food preparation surface which is easily disposedof while securely containing contaminants; and

[0011] 5. a single-use cutting surface that lays flat during use.

[0012] Coggins U.S. Pat. No. 5,520,945 discloses a disposable sheet thatmay be used in food service applications to prevent thecross-contamination of foods and eliminate the need for time-consumingclean-ups. The sheet comprises a porous layer that allows materials suchas oil or flour to pass through, an absorbent layer that holds thematerials passing through the porous layer, and a barrier layer thatensures that the materials do not contaminate a food preparationsurface. The sheet has multiple uses such as for rolling dough,absorbing excess moisture, making sandwiches, cutting breads andcondiments, and drawing excess oil away from fried items. The disposablesheet is only disclosed for use with items that do not requireaggressive cutting, and hence, is not adapted for use with items thatrequire substantial cutting pressures, such as meats and hardvegetables.

[0013] Thompson U.S. Pat. No. Re. 36,717 discloses a flexiblepreparation and transfer sheet. The sheet comprises a homogeneousstructure of polypropylene, with a thickness in a range between 0.010 to0.030 inch. The sheet may be flexed about a longitudinal centerlinewhereupon the sheet material develops a cantilever beam strengthsufficient to transport food articles after preparation to anappropriate container.

[0014] Wu et al. U.S. Pat. No. 6,021,524 discloses a polymeric filmhaving increased cut resistance. The film comprises a polymeric matrixhaving a plurality of cut resistance fibers dispersed therein. The filmis preferably made into medical or industrial gloves.

[0015] Otten et al. U.S. Pat. No. 6,274,232 discloses an absorbent andcut-resistant sheet having a cut-resistant material with a plurality ofopenings, and an absorbent material attached to the cut-resistantmaterial. A liquid impervious backing layer is preferably attached tothe absorbent material to resist the escape of fluid from the absorbentmaterial.

[0016] PCT published application number WO 00/29209 discloses a flexiblemat for absorbing liquids on floors or other surfaces. The mat includesa waterproof backing layer and a foam sheet formed by polymerization ofa water-in-oil emulsion. The mat can optionally include a liquidpervious sheet and a non-skid material.

SUMMARY OF THE INVENTION

[0017] In accordance with one aspect of the present invention, aprocessing substrate includes a sheet having a surface capable ofwithstanding cutting by a serrated knife without substantial compromiseof the sheet, a liquid impervious barrier and a liquid absorbent portiondisposed adjacent the surface.

[0018] According to a further aspect of the present invention, aprocessing substrate comprises first means for providing aliquid-permeable, cut resistant surface capable of withstanding cuttingby a serrated knife without substantial compromise of the processingsubstrate, second means disposed adjacent the first providing means forproviding a liquid-absorbent portion and third means disposed adjacentthe second providing means for providing a liquid-impermeable portion.

[0019] According to a further alternative aspect of the presentinvention, a method of forming a cutting surface comprising the steps ofproviding a first material having a liquid-permeable, cut-resistantsurface that can withstand cutting by a serrated knife withoutsubstantial compromise of the first material, providing a secondmaterial disposed adjacent the first material and having aliquid-absorbent portion and providing a third material disposedadjacent the second material and having a liquid-impermeable surface.

[0020] In accordance with yet another aspect of the present invention, amethod of processing an item comprises the steps of providing aprocessing surface comprising a first material having aliquid-permeable, cut-resistant surface that can withstand cutting by aserrated knife without substantial compromise of the first material, asecond material disposed adjacent the first material and having aliquid-absorbent portion and a third material disposed adjacent thesecond material and having a liquid-impermeable surface, placing theitem on the processing surface and processing the item while the item ison the processing surface. The item is then removed from the processingsurface and the processing surface is disposed of.

[0021] In accordance with a further alternative aspect of the presentinvention, a single use processing substrate comprises a firstcut-resistant layer having a first surface area and comprising athermoplastic material ply and a tissue ply and a second layer having asecond surface area and comprising a thermoplastic material ply and atissue ply, wherein the first layer is secured to the second layer suchthat a portion of the second surface area is laterally disposed outsideof the first surface area.

[0022] Other aspects and advantages of the present invention will becomeapparent upon consideration of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1A comprises an isometric view of a processing substrateaccording to a one embodiment the present invention;

[0024]FIG. 1B comprises an isometric view of a processing substrateaccording to another embodiment of the present invention;

[0025]FIG. 2 comprises a side elevational view of the processingsubstrate of FIG. 1; and

[0026]FIG. 3 comprises a sectional view taken generally along the lines3-3 of FIG. 1; and

[0027]FIG. 4 comprises a perspective view of apparatus for producingprocessing substrates as shown in FIGS. 1A.

[0028]FIG. 5 comprises an isometric view of a processing substrateaccording to another embodiment of the present invention;

[0029]FIG. 6 comprises an isometric view of a processing substrateaccording to another embodiment of the present invention.

[0030]FIG. 7 comprises a cross sectional view of FIG. 6.

[0031]FIG. 8 comprises an isometric view of a processing substrateaccording to another embodiment of the present invention.

[0032]FIG. 9 comprises an isometric rear view of a processing substrateaccording to FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Referring now to FIG. 1A, a processing substrate and/or supportsurface that may be used as a food preparation surface or sheet 10according to the present invention preferably is planar (i.e., flat) inshape. Alternatively, as seen in FIGS. 1B and 2, the sheet 10 may betray-shaped and includes a substantially planar central portion or base12 and inclined or curved side surfaces 14 a-14 d, wherein the base 12and side surfaces 14 together define a generally concave structure. Theside surfaces 14 may be formed by folding and/or scoring the sheet 10 atcorner portions 15 a-15 d and optionally folding or scoring the sheet 10at portions 13 a-13 d intermediate the base 12 and side surfaces 14. Theinclined or curved side surfaces 14 could alternatively be formed by anyother process, such as forming through the application of heat, vacuumforming, vacuum pressure forming, or the like. If desired, fewer thanfour inclined side surfaces 14 may be provided. For example, only theinclined side surfaces 14 a-14 c may be employed to provide a flat edgesurface that may be oriented toward the user so that an inclined sidesurface does not interfere with the user's hands or arms. Preferably,although not necessarily, the sheet 10 is intended for one time use as acutting surface or as a sheet supporting an article or as a barrier forisolating an article resting on a surface (for example, a plant on ashelf, an article of food on a counter or in a microwave, or the like),or as a food preparation and bacteria management sheet. Following theuse the sheet 10 and any waste products and contaminants carried therebymay be disposed of in any suitable fashion. The concave or tray-shapedstructure (if used) facilitates retention of the waste products andcontaminants during the food preparation, transport and/or disposalprocesses. Additionally or alternatively, the sheet 10 may besufficiently flexible to allow the user to bend and/or fold the sheet 10to prevent escape of waste products and contaminants therefrom duringdisposal.

[0034] Referring also to FIG. 3, according to one embodiment of thepresent invention, the sheet 10 also includes a cut-resistant,liquid-permeable top or upper portion or layer 16, which substantiallyprevents the integrity of the sheet 10 as a whole (and, in particular,the layer 16) from being compromised during cutting while at the sametime allowing passage of juices and liquids through the layer 16.Preferably, the upper portion or layer 16 is made of a materialsufficiently durable to withstand aggressive cutting of meats,vegetables and other food items by a serrated or non-serrated blade,particularly in the situation where a cutting motion is applied tomeats, poultry or fish (or any other fibrous protein material) thatresults in the application of cutting force components in multipledirections to the item. A serrated blade presents a series of equally ornon equally spaced points or tips to the upper surface of the layer 16that can snag or otherwise catch on edges of the material used for thetop layer 16. Because of this it is generally preferred (although notnecessarily the case) that the top layer 16 have irregularly or randomlyspaced openings therein that prevent any points or tips from contactingmaterial below the layer 16 during cutting. In this way, the possibilitythat the integrity of the sheet 10 would be compromised is reduced.

[0035] In addition to the foregoing, the upper portion or layer 16preferably has an upper surface 17 that is textured or otherwise formedto prevent slippage of items thereon during processing.

[0036] The sheet 10 further includes a middle or intermediate portion orlayer 18 that may be made of a liquid absorbent material that retainsthe juices and liquids passed by the upper layer 16, as well as a bottomportion or layer 20, which is preferably made of a slip-resistant,liquid and bacteria impervious material to prevent slipping of the sheet10 and leakage of liquids and transfer of bacteria onto or from a worksurface (such as a countertop, a cutting board, or the like) during use.

[0037] The upper layer 16 may be of a length and width substantiallyequal to the length and width of the middle layer 18. Alternatively, theupper layer may be of a smaller size than the size of the layer 18,thereby providing a cutting surface that is partially or fullysurrounded by portions of the middle layer 18. As a further alternative,the top and bottom layers 16, 20 may be of the same size and the middlelayer may be of a smaller size and so arranged relative to the layers 16and 20 such that the middle layer 18 is surrounded by the joined outermargins of the layers 16 and 20.

[0038] If desired, the sheet 10 may instead include a different numberof layers or portions each imparting one or more desiredcharacteristic(s) to the sheet 10. In addition, the sheet 10 maycomprise a single layer or portion or multiple layers or portionswherein each layer or portion is made of material that is differentiallytreated during production to obtain multiple desired characteristics.Still further, the sheet 10 may include one or more layers or portionsthat are not differentially treated during production in combinationwith one or more layers that are differentially treated duringproduction. For example, the sheet 10 could comprise a single layer thatis liquid absorbent, but which has a first surface that is treated (byany suitable process, such as the application of heat or a chemicaladditive) during production to produce a cut-resistant, liquid-permeablesurface. The sheet 10 may further have a second surface opposite thefirst surface that may be treated by any suitable process (for example,as noted above) during production to produce a slip-resistant barriersurface. Alternatively, the sheet 10 could comprise two layers, a firstof which provides a slip-resistant barrier surface, and a second ofwhich provides a cut-resistant surface. In this case, the liquidabsorbent layer may be omitted, or the liquid-absorbent material may beprovided as part of one of the first or second layers or as a separatelayer. Still further, the slip-resistant surface and/or thecut-resistant, liquid-permeable surface could be omitted, if desired.

[0039] The various layers 16, 18 and 20 are secured or formed togetherin any suitable fashion taking the various materials of the layers intoaccount. For example, two or more of the layers 16, 18 and 20 may beheated to fuse the layers together or the layers may be laminated aspart of an extrusion process. Two or more of the layers could instead besecured together by an adhesive including a hot melt adhesive as well asa solvent or water based adhesive, as long as the adhesive is approvedfor food contact and compatible with the layers. Alternatively, two ormore of the layers 16, 18 and 20 may be formed using materials and/or amanufacturing process which result in simultaneous formation and bondingof such layers. Still further, the layer 16 may be bonded or otherwisesecured to the layer 20 at selected locations, thereby capturing thelayer 18 therebetween. In this case, the layer 18 may have one or morevoids therein to facilitate the joinder of the layers 16 and 20 at thelocation(s) of the void(s). Still further, the layer 18 may be omittedand the layers 16 and 20 may be joined at spaced locations to createvoids between the layers 16, 20 which serve to attract and retainliquid(s) therein by capillary action.

[0040]FIG. 4 illustrates apparatus that may be used to produce a numberof cutting surfaces as shown in FIG. 1A. An extrusion die or otherdelivery device 40 deposits thin streams of molten thermoplastic onto aweb 42 of liquid-absorbent material, such as cellulosic tissue orbatting. The material deposited on the web 42 is chosen from but notlimited to polyolefins, such as polyethylene (PE), polyolefinmetallocenes, metallocene polypropylene (mPP) or polypropylene (PP)including homopolymers and copolymers thereof, polyester, such aspolyethylene terephthalate (PET), polystyrene (PS), polyvinyl alcohol(PVA), polyvinyl chloride (PVC), nylon (such as nylon 6 or nylon 66),polyacrylonitrile (PAN), ABS, ethylene-vinyl acetate (EVA) copolymer,multi layers of the same or different polymers, blends and recycledpolymers (including polymers that are cured by ultraviolet or visiblelight, an electron beam, water or other curing agent). Addition of oneor more filler(s) may be advantageous both from a cost advantage as wellas improvement of modulus, heat distortion and cut resistance.Preferably, each stream is approximately on the order of 1-100thousandths inch wide and are deposited at equally-spaced locations onthe web 42 approximately 1-500 thousandths inch apart. Alternatively,the streams may be deposited at non equally spaced locations on the web42 and/or may be of differing widths and/or may be deposited atdifferent points of time. Still further, different stream shapes (e.g.,a wavy, curved, discontinuous or interrupted stream as opposed to thelinear continuous stream extent described above and/or a differentcross-sectional shape) and/or different materials could be sequentiallydeposited on the web 42. In other words, a single stream may comprise afirst portion of a first material, a second portion deposited after thefirst portion of a second material, a third portion deposited after thesecond portion of a third material or the first material, etc. In analternative embodiment, adjacent streams may be of differing materials.In a general sense, N different materials may be deposited or otherwiseformed in situ on the web 42 in a repeating or non-repeating sequence orpattern or in a random fashion. In the case of a repeating sequence orpattern, the repetition frequency may be established at a value lessthan or equal to N. In any event, the choice of materials, sequence orpattern, and the like affect the physical characteristics of theresulting surface.

[0041] If the upper layer 16 is to be smaller than the size of the layer18, then the streams are deposited only on a center portion of the web42. In addition, the flow of thermoplastic resin is periodicallyinterrupted so that discrete portions of web are formed havingthermoplastic thereon wherein such portions are separated by further webportions not having thermoplastic deposited thereon. The web 42 thenpasses between a pair of rolls 44 a, 44 b. Preferably, the roll 44 a issmooth and the roll 44 b has a plurality of diamond-shaped or othershaped protrusions 46 on the surface thereof. The protrusions 46 deformand spread out the still molten thermoplastic streams to transform thelinear streams into a desired two or three dimensional pattern ofthermoplastic resin on the web 42. The web 42 then passes between one ormore additional pairs of rolls 48 that further spread out and/or flattenthe thermoplastic streams and impart a desired texture thereto. Theresulting surface provides cut resistance and prevents food from slidingthereon

[0042] If desired, any pattern can be created on the web 42, forexample, a random pattern or a crisscross pattern could be created bydrizzling, spraying or otherwise applying the material thereto.

[0043] Thereafter, the web 42 is inverted (i.e., turned over) and thelayer 20 is formed in situ by lamination or other delivery of athermoplastic or other material onto an undersurface 50 by an extrusiondie or other delivery apparatus. The layer 20 may alternatively beformed without first inverting the web 42 by any suitable process. Thelayer 20 may be formed of any of the materials described above inconnection with the layer 16 including polyolefins such as PE or PP,polyesters such as PET, PS, PVA, PVC, nylon, PAN, ABS, EVA, etc . . . Inalternative embodiments, 20 a suitable coating material may be appliedby a sprayer and mechanically processed by a doctor blade or a portionof the material of the layer 18 may be melted or otherwisedifferentially processed as noted above so that a sealed portion isobtained (if the material of the layer 18 so permits). Still further, abarrier layer of Tyvek® (sold by E. I. Du Pont de Nemours and Company ofWilmington, Del.) may alternatively be secured to the underside of theweb 42 by any suitable means.

[0044] The layer 20 may be formed with a pattern or texture by embossingand/or may be coated or laminated or otherwise formed with aslip-controlling (such as slip resistant) or adhesive material. The slipcontrol may be provided by a continuous or discontinuous surface of thelayer 20, as desired. The resulting coated web is then cut atappropriate locations to form the cutting sheets. Alternatively, ifdesired, the product may be delivered to the consumer in roll form sothat the consumer may cut the product to a desired length and/or shapeusing a cutter bar, scissors or knife. Still further, the product may bedelivered in roll form with perforations that allow the consumer to tearoff sheets as needed.

[0045] The present invention is not limited to the concept of utilizingdisposable, absorbent barrier surfaces in place of conventional cuttingboards, but encompasses all food handling and article support occasionswhere absorbent, liquid/bacteria barrier management is desirable. Thepresent invention comprehends arrangements of various barrier, absorbentand cut/physical abuse resistant mechanisms for the management bycontainment or isolation of wastes and bacteria encountered during foodprocessing, such as cutting, draining and accumulating (staging). All ofthese processes involve the use of a generally horizontal work surface,where the present invention may be advantageously employed. In general,the invention comprehends the use of N layers or other portions whichmay be arranged in a suitable or desired fashion to obtain the desiredmechanical, absorbent, barrier and/or other characteristics.

[0046] The preferred embodiment utilizes the cut resistant layer 16 asthe top layer, where the cutting operation is performed. If desired, thelayer 16 may be omitted and the cut-resistant surface could instead beprovided as part of the bottom layer 20. In this case the cut-resistantsurface would need to be impervious to liquid and the material of themiddle layer 18 could be exposed directly to the item being cut. Thisalternative may result in the possibility of material transfer from thelayer 18 to the food, although such possibility can be minimized throughcareful control of materials and design. For example, in an embodimentwhere the liquid absorbent layer 18 is the top layer, effort should bemade to ensure minimum transfer of material (e.g., fibers) to the foodbeing cut. In the case of paper, woven or nonwoven fabrics as thematerial of the liquid absorbent layer 18, thermal bonding of fiber tofiber in such layer and/or fiber of such layer to the material of thebottom layer 20 significantly reduces fiber transfer to the food. Manyother commercially available techniques for minimizing transfer ofmaterial(s) exist. For example, various thermal embossing patterns couldbe used. Care should be taken to ensure that the absorptive capacity ofthe material of the layer 18 is minimally affected by the mode ofbonding.

[0047] Other arrangements can be envisioned, such asthermoplastic/cellulosic conglomerates or agglomerates. In thesearrangements thermoplastic and cellulosic absorptive materials arecompressed together or otherwise processed and/or combined to form a cutresistant, absorptive sheet. When a thermoplastic liquid barriercomponent is fused on one side, a cut resistant, absorptive, barriersystem is formed.

[0048] Still further, each layer or portion may be “tuned” (in otherwords, the material selection, properties and/or amounts may becontrolled) to obtain the desired attributes and properties for each.For example, a first sheet could be designed for cutting chickencomprising an upper layer of PE or PP, a middle layer of cellulosicabsorbent material and a barrier layer of polymeric material asdescribed above in connection with FIG. 4. A second sheet couldalternatively be envisioned for light food preparation (such asassembling sandwiches from pre-cut foods) including the same threelayers in different proportions. This might comprise an upper layer ofPE or PP having a thickness substantially less than the thickness of theupper layer of the first sheet, a middle layer of cellulosic absorbentmaterial identical to the material of the middle layer of the firstsheet and a barrier layer of polymeric material identical to thematerial of the barrier layer of the first sheet. The thicknesses of themiddle and barrier layers of the second sheet may be different than oridentical to the thicknesses of the same layers of the first sheet. Thisprovides a sheet having lesser cut resistance than the first sheet, butstill provides a sheet having the desired absorbency and barriercharacteristics appropriate to the intended application for the sheet.Still further, the cellulosic material of the middle layer might bereplaced by a more oleophilic material, such as nonwoven polypropyleneor the same or a different cellulosic material that has been treated toincrease the oleophilic properties thereof, to form a sheet for managingoil during food preparation.

[0049] The present invention provides a processing and/or supportsurface that retains liquids yet is convenient and space effective foreasy disposal. The product may be pre-treated for packaging purposesand/or to allow easy and convenient disposal. Examples of pretreatmentfor easy disposal include pleating, folding, scoring, forming and thelike.

[0050] As noted above, the cut resistant top layer 16 may be made from arandom or regular pattern of thermally formable material or coatingmaterials. In addition to the examples given above, the material of thelayer 16 may comprise latexes, epoxies, paper coating and a contact drumprint that is treated by a doctor blade. Still further, a continuoussheet of polymer film could alternatively be used in place of thecut-resistant upper layer described in conjunction with FIG. 4 whereinthe film is perforated by any suitable process, such as vacuum, needleor water jet perforating, laser, hot pins or mechanical punching tocreate holes for the passage of liquid therethrough. A minimum holediameter of between about 0.060 and about 0.125 thousandths inch ispreferred. Less than 8 holes/square inch (depending upon hole size(s))is preferred. The spacing between the tips of serrated knife bladesvary; however, the smaller the hole diameter the less the chance that atip of such a blade will catch on an edge of a hole. The film can bemade of virgin polymer or blends of virgin and recycled materials orfrom recycled materials alone. As noted above, fillers or pigments toincrease opacity, optimize desired properties, and/or reduce cost areoptions. Alternatively, porosity can be achieved using differentprocesses such as pre- or post-lamination, lost mass process, leachingor scavenging.

[0051] The cut resistant layer 16 can alternatively comprise other cutresistant structures, such as netting, fabrics or scrims, so long as thelayer allows easy passage of juices and other liquids through to theabsorbent layer 18. In each embodiment the minimum thickness for thelayer 16 is approximately 5 mils for unfilled materials, but it may bepossible to achieve adequate cut resistance with thinner arrangements.

[0052] Care should be taken to use food contact approved materials. Theuse of a discontinuous layer affords a cut resistant barrier that keepsthe material of the layer 18 from the surface of the item being cut.Also, the discontinuous layer lends itself to being easily disposed ofdue to ease of “wadding” by the user

[0053] The liquid-absorbent layer 18 preferably is an absorbentstructure selected from, but not limited to: non-woven fabrics ofsynthetic polymers or blends of fibers; laminates of various fabrics orcombination of fabrics; cellulosic material(s), meltblown and spunbondednonwoven fabrics, woven fabrics, multiple layers and combinations offabrics and papers, adsorbent powders like polyacrylic acid polymers,open-celled foams, perforated closed cell foams and/or blends of polymerand cellulosic materials. The layer 18 could alternatively comprise anyother suitably absorbent commercially available materials.

[0054] If a synthetic polymer fabric, woven or nonwoven, is used for thelayer 18, a food-contact approved wetting agent or other surfaceadditive may be required to ensure water wettability of the fabric.Typical levels are <1% by weight of the fabric. Some hydrophilic fiberscan be used for layer 18 in blends with synthetic polymers to eliminatethe need for surfactants. Examples of these hydrophilic fibers arecellulose, rayon and PVA; however, the present invention is not limitedto these hydrophilic fibers. In some cases lamination of two differentfabrics may be necessary to obtain sufficient hydrophilic properties.However, it is preferred in this example to use a blend of fibers in onefabric. Typically, a minimum of 5 to 10% hydrophilic fiber is needed ina fiber blend to ensure that the fabric has sufficient hydrophilicproperties. An additional benefit of using fiber blends in the layer 18is the possibility to use different polymers in the layer 16 and stillemploy thermal bonding of the layers.

[0055] The bottom layer 20 forms a barrier to prevent liquids from theabsorbent layer from passing through to the surface of the counter topor other support surface. The bottom layer 20 also blocks the transferof bacteria between the layers 16 and 18 and the surface supporting thesheet 10. The bottom layer 20 can be any substrate material thatprevents passage of liquid therethrough. For example, the layer 20 maycomprise a continuous sheet of PP or PE film (or any other polymer film,such as those noted above) having a thickness on the order of 0.25-5.0mils, although a different thickness could be used instead. Fillersand/or coloring agents or other additives can be utilized to obtain thedesired characteristics, color and/or opacity. Like the layer 16, thefilm can be made of virgin polymer or blends of virgin and recycledmaterials or from recycled materials alone. Typically, the layer 20 isfabricated of materials chosen from a group of materials that willthermally bond to the layer adjacent thereto (in the preferredembodiment the layer 18), thereby obviating the need for adhesives,which are costly and can adversely affect the desired characteristic(e.g., the absorbent nature) of the adjacent layer.

[0056] In summary, the present invention comprehends any structure(single layer or multilayer, conglomerates, agglomerates, foams, productsuspended in one or more matrices or suspensions) having cut resistantproperties, liquid-absorbent properties and/or barrier properties. Theproperties may be afforded by any suitable processing technique(s), suchas coating or other application of product, denaturing or other changein a material (whether by flame treating or other application of heat,chemicals, irradiation, UV, IR or visible light, etc . . . ), mechanicalor electrical processing, or the like. In addition, the variousmaterials may be selected from ecologically advantageous materials thatbiodegrade.

[0057] In the case of foams, these can be either of the open-cell orclosed cell type made from conventional polyolefins or polyolefin filledmaterials. Still further, a foam can be filled with combinations of anyof the non-conventional materials listed below, such as egg whites andshells or other foams could be used with fillers like mica, starch, woodflour, calcium carbonate and flax. Other suitable materials may be breadimpregnated with adhesive binders, foamed potato starch or polyvinylacetate with any number of fillers like ground bone, lime or talc. Othersuitable foams are polyvinylpyrollidone aggregate open cell foams and PEand PP aggregate foams. Such combined materials can provide cutresistance and/or liquid absorption properties.

[0058] Hollow fibers could also be employed. In this case, hollow fibersof a critical diameter may be used to suck up and retain water bycapillary action. These fibers could possess cut resistant properties aswell as liquid management properties and a barrier layer could besecured by any suitable means to a mat of such fibers to obtain aprocessing surface according to the present invention.

[0059] The following materials possess one or more of the aboveabsorptive properties, cut resistance properties and barrier propertieseffective to manage bacteria or liquids during the preparation of food.Accordingly, any of these materials can be used in the presentinvention. Some are very eco-effective in that they decompose directlyto food for biocycles and many do not absorb microwave energy and aresafe for use as a support surface in microwave ovens:

[0060] “Earth shell” (a composition of potato starch and limemanufactured and/or sold by E. Khashoggi Industries, LLC of SantaBarbara, Calif.);

[0061] clay or clay-filled materials optionally reinforced withmaterials such as ground corncobs, silica, irradiated waste sludge orwoven straw;

[0062] kelp and other marine vegetation;

[0063] ground marine shells (e.g., lobster, crab, shrimp or any otherexoskeletal creatures, oyster, clam, scallop or zebra mussel shells)held together by a binder or matrix of any suitable material, such asbarnacle adhesive;

[0064] cork;

[0065] wood or wood product derivatives and veneers; natural fibers likecotton or wool either woven or in non woven batts;

[0066] materials such as flour, silica, rice, rice kernel, rice germ orstarch of any kind (e.g., corn or potato starch) either alone or heldtogether by a binder such as polyvinyl acetate or held together asconglomerate or agglomerate systems by any appropriate material(s);

[0067] animal, insect and/or fish products including shells, skins,hides, hooves, glues made from hides or hooves, scales or bones; otherprotein glues or glues from other products (such as gluten);

[0068] egg white or egg yolk composites with flour, rice, egg shells,flours with yeast, corn starch or potato starch;

[0069] lecithin;

[0070] polymeric substances created from high temperature treatment, orother breakdown, of carbon chains predominantly in sugars and oils, suchas is found in apples, grapes, cherries or other fruit (skins and/orpulp) olives (skins and/or pulp), olive oil, corn oil, vegetable oil,canola oil, or eggs;

[0071] bioengineered cell growth materials;

[0072] grasses and other terrestrial vegetation;

[0073] bark;

[0074] nonwoven microfibers;

[0075] cellular absorption swellable materials (such as Drytech® sold byThe Dow Chemical Company of Midland, Mich.);

[0076] molecular sieve materials (e.g., a desiccant); and

[0077] hydrophilic powders, like polyacrylic acid or the like.

[0078] Another embodiment of this invention can be seen in FIGS. 5-9. Asseen in FIGS. 5-9, a bilayer single use processing substrate comprises afirst two-ply cut-resistant layer 60 and a second two-ply layer 62. Thefirst layer has a first surface area 64 and comprises a tissue ply 66disposed below a thermoplastic material ply 68. The tissue ply 66 has athickness in the range of between about 2 and about 6 mils and thethermoplastic material ply 68 has a thickness in the range of betweenabout 4 and about 8 mils. The second layer 62 has a second surface area70 and comprises a tissue ply 72 disposed above a thermoplastic materialply 74. The tissue ply 72 has a thickness in the range of between about2 and about 6 mils and the thermoplastic material ply 74 has a thicknessin the range of between about 1 and about 5 mils. The first layer 60 isdisposed atop the second layer 62 such that the first layer tissue ply66 and the second layer tissue ply 72 are secured to each other by suchmeans as an adhesive or a water soluble polyethylene oxide coating onfirst and second layer tissue plies 66, 72, and wherein a portion of thesecond surface area 70 is laterally disposed outside of the firstsurface area 64.

[0079] The adhesive (not shown) can be applied either to the entiresurface of the first layer 60 or can be applied in any number ofpatterns, including without limitation interrupted patterns such as aseries of spaced spots and continuous patterns such as parallel stripesor interlocking stripes. One preferred pattern is a series of parallelstripes. It has been found that this pattern adds a capillary effect tothe processing substrate by slightly separating the sheets. Thisseparation creates a capillary effect that helps draw liquids away fromthe surface of the cut resistant layer 60. Also, these parallel stripeschannel the liquid toward that portion of layer 62 that is not coveredby layer 60 in the preferred embodiment.

[0080] Each of the first and second layers 60, 62 can be produced byextrusion coating the thermoplastic material ply onto the tissue ply ina manner similar to the process illustrated in FIG. 4. While thethermoplastic material plies can be formed from any of the thermoplasticmaterials described above, a preferred material is an isotacticcopolymer metallocene polypropylene, wherein the metallocenepolypropylene comprises between about 95 and about 99.95, and preferablybetween about 99.5 and about 99.9 percent by weight of a propylenemonomer and between about 0.05 and about 5, and preferably between about0.1 and about 0.5 percent by weight of an ethylene monomer.

[0081] The surface of each thermoplastic material ply can range fromsmooth to rough. While the two surfaces can both have similar surfacecharacteristics, in one preferred embodiment, the top surface of the cutresistant layer 60 can be smooth and the bottom surface of the secondtwo ply layers can be rough or have a matte appearance. The method ofcreating these surface effects is well known to those skilled in the artof film production. One method of producing these effects is to use afilm casting roll that mirrors the desired roughness of the film. Forsmooth films the roll can have a root mean square of about 0.5 to about10 and for the matte surface the roll can have a root mean square ofover about 100.

[0082] The most preferred resin composition comprises between about 90and about 100 by weight of the metallocene polypropylene and can furtherinclude any combination of the following components: an additiveselected from the group of talc, mica, wollastonite, calcium carbonate,barite, glass spheres and fibers, carbon fibers, and ceramic spheres,present in an amount of between about 0 and about 10 percent by weight,a food contact grade alkali metal stearate such as calcium stearate,magnesium stearate and the like or a food contact grade transition metalstearate such as zinc stearate and the like present in an amount ofbetween about 0.01 and about 0.1 by weight, and one or moreantioxidants, such as Alvinox P, Irgaphos 168, Alkanox 240, Iraganox3114, Iraganox 1010, Anox IC 14, and Alvinox FB, present in an amount ofbetween about 0 and about 0.25 by weight. Small amounts of otheradditives (nucleation agents, clarifiers and pigments) or processingaids can also be included so long as they do not negatively affect theoverall performance properties of the material. Preferably, additivesmust be approved for direct food contact. It is believed that the talcadditive speeds crystalline formation in the polypropylene and improvesthe cut resistant properties of the polymer, whereas a transition metalstearate serves as a film lubricant for the polypropylene duringprocessing.

[0083] The first layer tissue ply 66 and the second layer tissue ply 72are provided by an outside paper provider such as Little RapidsCorporation. Each of the first and second layer tissue plies 66, 72comprise a virgin hardwood and softwood wood pulp present in an amountof between about 90 and about 100 percent by weight of the tissue, apolyamide or other synthetic fiber present in an amount of between about0 and about 10 percent by weight of the tissue ply and can include oneor more of the following components in trace amounts: a defoamer, adryer release agent, one or more creping agents, a repulping aid and ableach neutralizer. The components present in trace amounts areadditives which are used as machine runnability aids for the tissue.

[0084] The first layer 60 has a surface area 64 less than the surfacearea 70 of the second layer 62 and is preferably substantially centeredon the second layer 62. In a preferred embodiment, the first and secondlayers 60, 62 have dimensions such that the surface area 64 of the firstlayer 60 is greater than 50 percent and less than 100 percent of thesize of the surface area 70 of the second layer 62. An arrangement oflayers can be used wherein first layer 60 is coextensive with the secondlayer 62 in a first dimension but is smaller than the second layer 62 inthe second dimension. Across the second dimension, the first layer 60can be centered or offset relative to the second layer 62. When thefirst layer 60 is centered, this forms areas or gutters of similarsizes. Where the first layer 60 is offset relative to the second layer62 in a second dimension, either a single area or gutter is formed alongone edge or two different sized areas or gutters can be formed. Thevisibility of that portion of tissue ply 72 of second layer 62 which isnot covered by first layer 60 provides positive reinforcement to theultimate user of the processing sheet of the present invention that thesheet has absorbent as well as protective characteristics.

[0085] In a commercial embodiment, the substrate may include the firstlayer 60 having dimensions of between about 6 inches and about 12 inchesby between about 5 inches and about 10 inches and the second layer 62may include dimensions of between about 10 inches and about 16 inches bybetween about 8 inches and about 13 inches. As seen in FIGS. 6 and 7,the first layer 60 may have regularly spaced apertures 76 therein topermit flow of fluids therethrough. While a preferred arrangement ofapertures is a zigzag pattern in the first layer 60, wherein theapertures 76 are separated from one another by between about 0.25 inchesand about 0.375 inches in the x-direction and between about 0.125 inchesand about 0.75 inches in the y-direction, any arrangement and density ofthese apertures can be used. As shown in FIG. 7, apertures 76 do notextend into or through the second layer 62. The apertures 76 are formedby any suitable process, such as vacuum, needle or water jetperforation, laser, hot pins or mechanical punching, wherein theapertures have a substantially circular geometry and a nominal diameterof between about 0.060 inches and about 0.125 inches. According to thedimensions of the first layer and the number of apertures therein, theaverage number of apertures per square inch is between about 0 and about8. An alternative aperture geometry can be regularly shaped rectangularor square apertures.

[0086] As seen in FIGS. 7 and 8, the first surface area 64 and theportion of the second surface area 70 disposed outside of the firstsurface area 64 may be formed with a pattern or texture 78 by embossing,wherein the step of embossing occurs after the substrate is assembled.This pattern or texture of embossing can be seen on a back surface 80 ofthe second layer 62 as seen in FIG. 9.

[0087] Further specific examples of structures according to the presentinvention are given below:

[0088] Example 1—a trilayer structure wherein the layer 16 comprises 5mil thick PP, filled with up to 40% mica and including {fraction(1/32)}″ diameter holes with 9 holes/square inch. The layer 18 is a 37#airlaid cellulose mat thermally laminated to a 5 mil thick PP backingsheet comprising layer 20. The layer 16 is thermally bonded to the layer18.

[0089] Example 2—a bilayer structure comprising a nonwoven polyolefinfabric upper layer point bonded to a second layer of polymeric film thatfunctions both as a barrier and as a cut resistant surface. Duringmanufacture a food-contact approved surfactant may be applied to theupper layer to provide a desired hydrophilic characteristic.

[0090] Example 3—a scrim made of any of a variety of materials, such asa thermoplastic or thermosetting polymeric material having voids betweenportions of material is post-filled with absorbent material, such ascellulose, using any suitable post-filling process, such as a wet-laidprocess or a vacuum process, to form a mat. A barrier layer of anysuitable material (e.g., PP or PE) is thereafter applied in any suitablemanner, such as by extrusion lamination, to an undersurface of the matand the mat is thereafter subjected to an embossing process either whilethe barrier layer is still partially molten and/or as heat is applied tocause the barrier layer to bond securely to the scrim.

[0091] Example 4—a bilayer single use processing substrate comprises afirst layer 60, wherein the tissue ply 66 is 2.5 mils thick and thethermoplastic material ply 68 is 5 mils thick. The second layer 62 has atissue ply 72 which is 2.5 mils thick and a thermoplastic material ply74 which is 3.5 mils thick, wherein the first layer 60 is secured atopthe second layer 62 by an ethyl vinyl acetate adhesive.

[0092] Each of the thermoplastic material plies consists of a resincomprising an isotactic copolymer metallocene polypropylene, wherein themetallocene polypropylene comprises 99.9 percent by weight of apropylene monomer and 0.1 percent by weight of an ethylene monomer. Theresin comprises 93.873 percent by weight of the metallocenepolypropylene, 6.050 percent by weight of a talc additive, 0.055 percentby weight of calcium stearate, 0.011 percent by weight of a primaryantioxidant, and 0.011 percent by weight of a secondary antioxidant.

[0093] The first and second layer tissue plies 66, 72 comprise 98percent by weight of a virgin hardwood and softwood wood pulp, 0.2percent by weight of a polyamide wet strength resin and trace amounts ofa defoamer, a dryer release agent, two creping agents, a repulping aidand a bleach neutralizer.

[0094] The first layer 60 has dimensions of 9.75 inches by 7.688 inchesand the second layer 62 has dimensions of 11.75 inches by 9.688 inches.The first layer 60 includes 414 regularly spaced apertures created byhaving a nominal diameter of 0.08 inches, wherein the apertures form azigzag pattern and are separated from one another by 0.279 inches in thex-direction and 0.165 in the y-direction. The average number ofapertures per square inch is 5.52.

[0095] The first surface area 64 and the portion of the second surfacearea 70 disposed outside of the first surface area are embossed withembossing pattern 78.

[0096] The present invention can provide one or more of the followingbenefits, depending upon the choice of material(s), properties andmaterial amounts:

[0097] 1. the sheet absorbs food juices while cutting and reducesresulting mess;

[0098] 2. the sheet is easy to dispose of;

[0099] 3. the sheet reduces or even prevents accidental germ/microbialcontamination because the germs from one food item will not gettransferred to another if the cutting sheet is disposed of after use;

[0100] 4. the sheet provides cut resistance, i.e., it helps reduce anycut damage to the kitchen or other work surface;

[0101] 5. the sheet does not allow food juices to run all over the worksurface;

[0102] 6. the sheets may be provided in varying sizes to suit thecutting or other task;

[0103] 7. the sheet may be used on top of a cutting board or directly onthe work surface;

[0104] 8. the sheet reduces slippage, by providing a skid-resistantcontact with the work surface;

[0105] 9. after cutting, one need only lift the sides of the sheet tofunnel food into a cooking pot;

[0106] 10. the sheet can be set on a surface to catch debris and grease;

[0107] 11. the sheet is easily rolled up with waste captured therein anddisposed of in the trash can;

[0108] 12. since each sheet is clean the need for repeated cleaning ofthe cutting board or other work surface is avoided;

[0109] 13. the sheet can be used to cut or process any food or othermaterial including meat, chicken, fish, soft or hard fruits andvegetables, dough, etc . . . ;

[0110] 14. unlike using a paper towel, the sheet does not permit fiberand lint to become attached to the food being cut.;

[0111] 15. the sheet does not transfer any smell or taste to the productbeing cut or otherwise processed (alternatively, the sheet could beimpregnated with a desirable scent, such as lemon, which is thentransferred to the item being processed);

[0112] 16. the sheet manages bacteria by absorption, containment andbarrier rather than by the use of added chemicals;

[0113] 17. the sheet can be made food contact approved;

[0114] 18. the top surface reduces slippage of food while cutting;

[0115] 19. the cutting surface will not dull knives like some hardcutting surfaces;

[0116] 20. the sheet is hygienic;

[0117] 21. the sheet may be formed with at least one and, preferablymultiple absorbent edges that give an extra measure of security tomanage bacteria-borne juices;

[0118] 22. the sheet offers superior food/surface protection fornon-cutting food preparation applications;

[0119] 23. the sheet affords an easy, convenient medium for in-home orout-of-home, recreational and outdoor uses;

[0120] 24. the sheet can be cut by consumers to other sizes and/orshapes;

[0121] 25. the sheet can be held in place on countertops by a few dropsof water;

[0122] 26. the sheet protects the countertop and food from potentiallydeadly pathogens that cannot be seen;

[0123] 27. the sheet allows safer food preparation for the consumer andthe consumer's family by reducing the risk of food-borne illness;

[0124] 28. the sheet can reduce food preparation time;

[0125] 29. the profile and/or texture of the cutting surface can becustomized to provide benefits not practical in conventional cuttingsurfaces or boards simply because such articles would be difficult orimpossible to wash;

[0126] 30. the sheets do not take up room in the dishwasher or in thebags and wraps drawer of the kitchen;

[0127] 31. in alternative embodiments bacteria borne liquids aresecurely trapped in cells and/or a layer below the cutting surface;

[0128] 32. the sheet may be constructed so that the consumer can see theabsorption of liquid;

[0129] 33. the sheet may be made to have a clean hygienic appearance;

[0130] 34. the sheet may have a decorative appearance that is printedand/or embossed as desired;

[0131] 35. the sheet absorbs like a paper towel, but has the additionaladvantages of barrier and cut resistance;

[0132] 36. the sheet has additional uses, for example, as a placemat, ascounter protection for use around stove/cook top, bin/shelf protectionin refrigerator, under dog or cat dish, under plants, under largeserving dishes, etc . . . ;

[0133] 37. in some embodiments the sheet has a place to wipe a knife on;

[0134] 38. the sheet can make a desirable addition to a picnic basket;

[0135] 39. the sheet can be used to line a refrigerator meat tray;

[0136] 40. the sheet absorbs and contains all juices from defrostingmeat;

[0137] 41. the sheet can contain odors from foods, such as fish;

[0138] 42. the sheet can be used on dishes and platters to preventscratching of same by knives;

[0139] 43. the sheet can be placed under sticky and dripping containersin refrigerator;

[0140] 44. the sheet does not fall apart like paper towels; and

[0141] 45. the sheet could be used as a drawer liner or as a mat to doart projects on.

[0142] Numerous modifications to the present invention will be apparentto those skilled in the art in view of the foregoing description.Accordingly, this description is to be construed as illustrative onlyand is presented for the purpose of enabling those skilled in the art tomake and use the invention and to teach the best mode of carrying outsame. The exclusive rights to all modifications which come within thescope of the appended claims are reserved.

[0143] Industrial Applicability

[0144] The present invention is not limited to the concept of utilizingdisposable, absorbent barrier surfaces in place of and/or in conjunctionwith conventional cutting boards, but encompasses all food handling,article support and barrier/isolation applications where absorbent,liquid/bacteria barrier management is desirable.

We claim:
 1. A single use processing substrate, comprising; a firstcut-resistant layer having a first surface area and including tissue plyand a thermoplastic material ply; and a second layer having a secondsurface area and including a tissue ply and a thermoplastic materialply, wherein the first layer is secured to the second layer such that aportion of the second surface area is laterally disposed outside of thefirst surface area.
 2. The single use processing substrate of claim 1,wherein the first layer tissue ply is disposed below the first layerthermoplastic material ply.
 3. The single use processing substrate ofclaim 2, wherein the first layer thermoplastic material ply is extrusioncoated onto the first layer tissue ply.
 4. The single use processingsubstrate of claim 1, wherein the second layer tissue ply is disposedabove the second layer thermoplastic material ply.
 5. The single useprocessing substrate of claim 4, wherein the second layer thermoplasticmaterial ply is extrusion coated onto the second layer tissue ply. 6.The single use processing substrate of claim 1, wherein the thickness ofthe first layer tissue ply is between about 2 to about 6 mils.
 7. Thesingle use processing substrate of claim 1, wherein the thickness of thesecond layer tissue ply is between about 2 to about 6 mils.
 8. Thesingle use processing substrate of claim 1, wherein the thickness of thefirst layer thermoplastic ply is about 5 mils.
 9. The single useprocessing substrate of claim 1, wherein the thickness of the secondlayer thermoplastic ply is about 3.5 mils.
 10. The single use processingsubstrate of claim 1, wherein the first layer thermoplastic ply and thefirst layer tissue ply include a plurality of apertures therein.
 11. Thesingles use processing substrate of claim 10, wherein the apertures arecreated by perforating.
 12. The single use processing substrate of claim10, wherein the apertures are created by punching.
 13. The single useprocessing substrate of claim 10, wherein the first layer thermoplasticply and the first layer tissue ply contain an average of 5.52 aperturesper square inch.
 14. The single use processing substrate of claim 10,wherein the apertures are a substantially circular.
 15. The single useprocessing substrate of claim 14, wherein the apertures have a diameterof about 0.08 inches.
 16. The single use processing substrate of claim10, wherein the apertures are regularly spaced.
 17. The single useprocessing substrate of claim 16, wherein a spacing between apertures iscreated in the x-direction by 0.279 inches and in the y-direction by0.165 inches.
 18. The single use processing substrate of claim 17,wherein the spacing between apertures creates a zigzag pattern in thefirst layer thermoplastic ply and the first layer tissue ply.
 19. Thesingle use processing substrate of claim 1, wherein the first layerthermoplastic ply and the second layer thermoplastic ply includes aresin comprising metallocene polypropylene.
 20. The single useprocessing substrate of claim 19, wherein the metallocene polypropylenecomprises a copolymer of propylene and ethylene.
 21. The single useprocessing substrate of claim 20, wherein the resin further includes atalc additive.
 22. The single use processing substrate of claim 21,wherein the talc additive is present in an amount less than about 10percent by weight of the resin.
 23. The single use processing substrateof claim 22, wherein the resin further includes calcium, magnesium orzinc stearate.
 24. The single use processing substrate of claim 23,wherein the resin further includes at least one antioxidant.
 25. Thesingle use processing substrate of claim 1, wherein the first layer issubstantially centered in the second surface area in at least onedirection.
 26. The single use processing substrate of claim 1, whereinthe first layer is substantially centered in the second surface area inboth directions.
 27. The single use processing substrate of claim 1,wherein the first surface area and the portion of the second surfacearea laterally disposed outside of the first surface area are embossed.28. The single use processing substrate of claim 1, wherein the firstlayer has dimensions of about 9.75 inches by about 7.688 inches.
 29. Thesingle use processing substrate of claim 1, wherein the second layer hasdimensions of about 11.75 inches by about 9.688 inches.
 30. The singleuse processing substrate of claim 1, wherein the first layer is securedto the second layer by adhesive.
 31. The single use processing substrateof claim 30, wherein the adhesive is ethyl vinyl acetate.
 32. The singleuse processing substrate of claim 30, wherein the adhesive is in apattern of parallel stripes.
 33. A single use processing substrate,comprising; a first cut-resistant layer having a first surface area andincluding a ply of tissue disposed below a ply of thermoplasticmaterial; and an unfolded second layer having a second surface area andincluding a ply of tissue disposed above a ply of thermoplasticmaterial, wherein the first layer is secured to and substantiallycentered on the second layer in at least one dimension such that aportion of the second surface area is laterally disposed outside of thefirst surface area.
 34. The single use processing substrate of claim 33,wherein the first layer tissue ply is disposed below the first layerthermoplastic material ply.
 35. The single use processing substrate ofclaim 33, wherein the first layer thermoplastic material ply isextrusion coated onto the first layer tissue ply.
 36. The single useprocessing substrate of claim 33, wherein the second layer tissue ply isdisposed above the second layer thermoplastic material ply.
 37. Thesingle use processing substrate of claim 36, wherein the second layerthermoplastic material ply is extrusion coated onto the second layertissue ply.
 38. The single use processing substrate of claim 33, whereinthe thickness of the first layer tissue ply is between about 2 to about6 mils.
 39. The single use processing substrate of claim 33, wherein thethickness of the second layer tissue ply is between about 2 to about 6mils.
 40. The single use processing substrate of claim 33, wherein thethickness of the first layer thermoplastic ply is about 5 mils.
 41. Thesingle use processing substrate of claim 33, wherein the thickness ofthe second layer thermoplastic ply is about 3.5 mils.
 42. The single useprocessing substrate of claim 33, wherein the first layer thermoplasticply and the first layer tissue ply include a plurality of aperturestherein.
 43. The single use processing substrate of claim 42, whereinthe apertures are created by perforating.
 44. The single use processingsubstrate of claim 42, wherein the apertures are created by punching.45. The single use processing substrate of claim 42, wherein the firstlayer thermoplastic ply and the first layer tissue ply contain anaverage of 5.52 apertures per square inch.
 46. The single use processingsubstrate of claim 42, wherein the apertures are a substantiallycircular.
 47. The single use processing substrate of claim 46, whereinthe apertures have a diameter of about 0.08 inches.
 48. The single useprocessing substrate of claim 41, wherein the apertures are regularlyspaced.
 49. The single use processing substrate of claim 48, wherein aspacing between apertures is created in the x-direction by 0.279 inchesand in the y-direction by 0.165 inches.
 50. The single use processingsubstrate of claim 49, wherein the spacing between apertures creates azigzag pattern in the first layer thermoplastic ply and the first layertissue ply.
 51. The single use processing substrate of claim 33, whereinthe first layer thermoplastic ply and the second layer thermoplastic plyincludes a resin comprising metallocene polypropylene.
 52. The singleuse processing substrate of claim 51, wherein the metallocenepolypropylene comprises a copolymer of propylene and ethylene.
 53. Thesingle use processing substrate of claim 52, wherein the resin furtherincludes a talc additive.
 54. The single use processing substrate ofclaim 53, wherein the talc additive is present in an amount less thanabout 10 percent by weight of the resin.
 55. The single use processingsubstrate of claim 54, wherein the resin further includes calcium,magnesium or zinc stearate.
 56. The single use processing substrate ofclaim 55, wherein the resin further includes at least one antioxidant.57. The single use processing substrate of claim 33, wherein the firstlayer is substantially centered in the second surface area in bothdimensions.
 58. The single use processing substrate of claim 33, whereinthe first surface area and the portion of the second surface arealaterally disposed outside of the first surface area are embossed. 59.The single use processing substrate of claim 33, wherein the first layerhas dimensions of about 9.75 inches by about 7.688 inches.
 60. Thesingle use processing substrate of claim 33, wherein the second layerhas dimensions of about 11.75 inches by about 9.688 inches.
 61. Thesingle use processing substrate of claim 33, wherein the first layer issecured to the second layer by adhesive.
 62. The single use processingsubstrate of claim 61, wherein the adhesive is ethyl vinyl acetate. 63.The single use processing substrate of claim 61, wherein the adhesive isin a pattern of parallel stripes.